Intrinsically Safe vs Explosion Proof Lights

Dec. 23, 2024

Intrinsically Safe vs Explosion Proof Lights

'Explosion Proof' and 'Intrinsically Safe' are the two most common, well known classes of lighting based on two different ways of preventing explosions in an atmosphere containing hazardous vapor. This includes handheld, portable, and wearable lighting, as well as complete facility lighting systems. The difference between the two classes of lighting is significant, and is based on the premise of Containment vs Prevention.

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The Containment (Explosion Proof) method allows the ignition to happen, but keeps it from spreading to an open atmosphere where it becomes dangerous.

The Prevention (Intrinsically Safe) method controls the source of ignition, and never allows for enough energy to make ignition possible.

Bottom Line: The safest, most representative method of prevention is using Intrinsically Safe devices.

Applicable Standards

Intrinsically Safe (IS) Standard

There are international safety standards that certify light systems as Intrinsically Safe:

FM Approvals, the independent testing arm of international insurance carriers, issues certifications (FM certification) for products that meet their standards in scientific tests
American National Standards Institute (ANSI) issues standards for "Explosive Atmospheres Performance" (ANSI/ISA -1 standards)
United Laboratories (UL) issues certification for lighting that is explosion-proof in hazardous atmospheres (UL )
In addition, the National Electrical Code (NEC) provides guidelines to electricians and others who install lighting in hazardous areas

An Intrinsically Safe rating means that the electronics or wiring contained within the equipment can not spark at all.

The lighting cannot accumulate enough energy to ignite the gas or vapor at its location
The surface temperature of the equipment that powers the lighting cannot get high enough to ignite the gas or vapor in its location

Explosion Proof (EP) Standard

Equipment with an explosion-proof classification does not mean that the lighting will survive an explosion (this is a common misconception). It means that the lighting is housed in an enclosure that will prevent an internal spark from causing an external explosion.

The enclosures are usually made of stainless steel or cast aluminum
If gases from a hazardous atmosphere should enter the enclosure, the enclosure is designed to contain any internal explosion caused by internal sparks
Explosion-proof lighting must be insulated sufficiently to meet the standard that, in the event of an internal explosion, the external surface temperature does not reach the ignition temperature of the gasses in the atmosphere

Hazardous Atmospheres

There are three recognized classes and two "divisions" of hazardous atmospheres that the lighting fixtures are judged against. The three classes are:

Class 1 are gases and vapors (the most explosive)
- Group A. Acetylene
- Group B. Hydrogen and manufactured hydrogen-containing gases
- Group C. Petrochemicals
- Group D. Methane
Class 2 consists of combustible dust
Class 3 consists of combustible fibers and "flyings"

There are two "divisions" of hazardous conditions within each class:

Division I: The gases or vapors are always present at sufficient concentrations to be an explosion hazard
Division II: The gases or vapors may be present, and if they are, they are likely to be at sufficient concentrations to be an explosion hazard

How Intrinsically Safe Lighting Works

Intrinsically safe lighting is low-powered lighting, often incorporating batteries and rechargeable batteries. This lighting often makes use of low-voltage bulbs, like light emitting diodes (LEDs). Halogen flashlights and high-intensity discharge lights (HID) are often classified this way.

In reality, intrinsically safe lights are based on designs that limit the amount of electrical energy used to non-incendive levels, so that sparks cannot occur at amperages and voltages that can cause explosions in hazardous atmospheres.

A typical fixed industrial IS lighting circuit would incorporate a temperature sensor installed in a way that limits the amount of energy to the light, based on the temperature. The lighting is controlled by ambient temperature, but must still meet high lighting standards.

High-intensity discharge lamps produce light in a transparent, sealed fused quartz tube or fused aluminum tube filled with gas and metal salts. An electric arc, started in the gas, heats and evaporates the metallic salts to form a plasma that intensifies the light caused by the arc itself. These high-intensity lights make light per unit of power more visible than fluorescent or incandescent bulbs. More of the energy produces visible light, rather than infra-red (heat) energy. However, the lights do use up the fuel (metallic crystals) and light levels drop by up to 70 percent over 10,000 hours of use.

The Pro's & Con's of Explosion Proof vs Intrinsically Safe

Explosion Proof devices are designed to allow ignition to occur, but to contain it so that it does not cause an external explosion.

The explosion-proof method is not limited to low-voltage lighting units.
The wiring of explosion-proof devices is well understood and straightforward.
The wiring of explosion-proof lighting is expensive due to the conduit, enclosures and seals; as well as the heavy-duty housing needed.
The housing of the lighting requires vigilant maintenance checks for damage and leaks.
Most experts agree that explosion-proof lighting involves greater continuous safety risks since the explosion is allowed to happen and disaster can follow if any imperfections are overlooked.

Intrinsically Safe devices never allow an ignition to happen in the first place.

Explosions can't happen, even in fault conditions like broken wires or outed circuit boards.
The process of wiring is much less involved than the explosion proof installation. It simply has to be wired to conform to electrical code.
Intrinsically safe devices do not require a stringent maintenance routine, because fire danger is not an issue. It does not require operators to evacuate rooms for testing and for programming instrumentation.
Intrinsically safe devices include many sources of lighting that are portable or hand movable and running on rechargeable batteries, which may themselves be connected to low voltage A.C.

In Summary

Intrinsically Safe lighting is widely considered as superior to Explosion Proof lighting for use in hazardous locations. CLICK HERE for a complete listing of BAYCO lighting products available from goSafe. For more information, contact your goSafe representative at

Everything You Need to Know About Explosion Proof ...

In hazardous environments like oil rigs, chemical plants, and refineries, choosing the right lighting is not just a matter of efficiency, but safety. Incorrect lighting choices can lead to disastrous consequences for the crew and the on-site infrastructure, making explosion-proof lighting critical.

This comprehensive guide will walk you through explosion-proof lighting standards, the technical details, and the various types of ex-proof lights available. We'll also explore material considerations, real-world case studies, and a comparison between explosion-proof LED lights and traditional lighting solutions. By the end of this blog, you&#;ll understand how to make an informed choice that not only meets regulatory requirements but also enhances safety and operational efficiency.

&#;&#; What is Explosion Proof Lighting?

Explosion-proof lighting is designed to prevent the ignition of hazardous materials like gases, dust, or vapours present in the surrounding environment. These lighting solutions are engineered to contain sparks or flames within the enclosure, preventing them from interacting with external elements.

Whether you're working in a chemical processing facility or a petrochemical refinery, explosion-proof lighting requirements play an essential role in maintaining safety and compliance with stringent industry regulations.
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&#;&#;Global Explosion-Proof Lighting Standards and Regulations

Explosion-proof lighting must meet several rigorous standards to ensure it can perform safely in hazardous locations. These standards vary globally but are aimed at achieving one common goal &#; preventing explosions in high-risk environments.

ATEX Certification (Europe)

In Europe, the ATEX directive governs explosion-proof equipment, including lighting. ATEX certification classifies hazardous environments into zones based on the likelihood and duration of explosive atmospheres.

Zone 0: Where explosive gases are present continuously or for long periods.
Zone 1: Where explosive gases are likely to be present during normal operations.
Zone 2: Where explosive gases are unlikely to occur but may exist for short durations.

Understanding these zones is essential when selecting explosion-proof area lighting to meet the required safety standards.

IECEx Certification (Global)

The IECEx certification is globally recognized and ensures products like explosion-proof lights meet international standards for explosive atmospheres. It is particularly important for industries operating across multiple regions, as it provides a harmonised approach to safety compliance.

National Electrical Code (NEC) (United States)

In the U.S., the NEC classifies hazardous locations into Division 1 and Division 2 areas, depending on the presence of flammable materials during normal or abnormal operating conditions. Similar to ATEX and IECEx, these divisions have stringent requirements that all explosion-proof light fittings must adhere to.

&#;&#; Key Explosion-Proof Lighting Specifications

Selecting the right explosion-proof lighting involves more than just compliance with standards. Various technical specifications play a role in ensuring the lights can safely and efficiently illuminate hazardous environments.

Voltage and Wattage

One of the most crucial factors in explosion-proof lighting specifications is choosing the correct voltage and wattage. High-risk environments require lighting that provides ample brightness without overloading circuits or causing electrical sparks.

For example, warehouses in hazardous areas might require lower wattage for energy conservation, but higher voltage to ensure adequate power distribution across large areas. This balance is vital in maintaining safety and meeting energy-efficiency goals.

Lumens Output and Light Distribution

The brightness of explosion-proof lighting is measured in lumens, and selecting the appropriate lumens output is essential for ensuring sufficient visibility. For large industrial areas like refineries, explosion-proof area lighting must provide high lumens output to cover vast spaces. The light distribution, or how evenly the light spreads, is another critical factor that can affect safety in high-risk zones. To calculate the necessary lumens for different industrial settings, you can use the formula: lumens = lux × area, where lux is the required illumination level for the specific task and area is measured in square feet or metres.

Temperature Ratings

Explosion-proof lighting must also be able to operate in high-temperature environments without igniting surrounding materials. Temperature classifications, ranging from T1 to T6, are assigned to explosion-proof lighting depending on the maximum surface temperature they can withstand. For example, a T6-rated light can function safely in environments where the maximum on-site temperature is 85°C, making it suitable for many industrial applications.

Enclosure Material and IP Ratings

The materials used in explosion-proof light fittings also play a pivotal role in ensuring the durability and safety of the lighting system. High-quality enclosures must be resistant to corrosion, extreme weather, and dust.

Ingress Protection (IP) Ratings: The IP rating determines how well a light fixture is sealed against foreign objects like dust or moisture. For example, an IP67-rated fixture has a high degree of protection against dust and water submersion for extended periods of time, making it ideal for outdoor explosion-proof lighting applications, particularly for onshore and offshore operations.

Battery Life

The battery life of ex-proof lights is another important consideration, particularly for the ones used for extended periods of time. Some models may offer longer battery life but may also be heavier due to the larger battery size. The features of each product needs to be compared with the expected deliverables from the light for the industry to make an informed and conscious choice. For instance, efficient portable lights with high battery life but heavy bodies might become a challenge for everyday operations and compromise the flexibility in surveillance that &#;portable&#; models offer.

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Additional Features

Several explosion-proof variants have additional features such as adjustable brightness, zoom capabilities, and SOS signals. Consider whether these features are necessary for your industry and invest in the lights accordingly.

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&#;&#; Exploring Different Types of Explosion-Proof Lighting

Explosion-proof lighting solutions come in several variations, each suited to specific environments and applications. Below are the primary types of explosion-proof lights and where they are commonly used.

Portable Explosion-Proof Lighting

Portable explosion-proof lighting is essential for tasks requiring temporary illumination in hazardous locations. These lights are highly durable, lightweight, and easy to transport. Industries such as mining, oil and gas, and chemical processing frequently use portable solutions for maintenance and inspections.

The portability of these lights, combined with their long battery life, ensures safety during short-term work without the need for fixed installations. This flexibility is particularly valuable in high-risk environments where fixed lighting might not always be practical.

Explosion-Proof Area Lighting

When it comes to illuminating large spaces like oil refineries, chemical plants, or industrial warehouses, explosion-proof area lighting is the go-to solution. These systems are designed to provide broad, uniform coverage, ensuring that every part of the workspace is well-lit and safe for operation.

The design of these lights often includes specialised reflectors to direct light efficiently across the area, reducing shadows and improving visibility.

Emergency Explosion-Proof Lighting

Emergency explosion-proof lighting is vital for ensuring safety during power outages in hazardous environments. These lights provide immediate illumination, helping workers safely evacuate or continue operations without the risk of accidents. Designed to withstand extreme conditions, they automatically activate in the event of power failure, ensuring uninterrupted visibility.

Industries like oil and gas, chemical processing, and manufacturing rely on emergency explosion-proof lighting to prevent accidents and maintain safety standards. Their robust construction and compliance with explosion-proof lighting standards make them essential in any hazardous environment.

&#;&#; &#;Applications of Explosion-Proof Lights in Hazardous Environments

Explosion-proof lights are essential tools in hazardous environments where flammable gases or dust particles are present. Here are some common applications of explosion-proof lights:

Oil and Gas Industry: In the oil and gas industry, explosion-proof lights are used to inspect and maintain equipment, as well as to illuminate work areas during drilling and production operations.

Chemical Plants: In chemical plants, explosion-proof lights are used to inspect and maintain equipment and to illuminate work areas during the production and handling of hazardous chemicals.

Inspection and Maintenance: In hazardous environments, regular inspection and maintenance of equipment are critical to prevent accidents. Explosion-proof lights are used to illuminate equipment and inspect it for damage or wear.

Emergency Response: In the event of an emergency, such as a power outage or fire, emergency explosion-proof lights provide reliable and high-quality lighting to guide workers to safety.

Confined Space Work: In tight spaces such as tanks, silos or pipes, explosion-proof lights are used to provide illumination and ensure safety while workers carry out their tasks.

Search and Rescue: In rescue operations, these lights provide bright and clear illumination in low-light or dark conditions, improving the chances of finding victims and rescuing them safely.

Mining Operations: Mining operations involve working in environments that are often dark and hazardous. Portable explosion-proof lights are used to provide bright and reliable lighting for workers to carry out their tasks safely.

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&#;&#; The Importance of Material Selection in Explosion-Proof Lighting

Selecting the right materials for explosion-proof lighting is essential to ensure long-term durability and safety, especially in environments where corrosive chemicals or extreme weather conditions are present.

Stainless Steel vs. Aluminum

When it comes to enclosure materials, stainless steel and aluminium are the two most commonly used metals. Stainless steel is highly resistant to corrosion, making it ideal for environments like offshore oil rigs or chemical plants, where exposure to harsh elements is frequent.

On the other hand, aluminium is lighter and more cost-effective, making it suitable for indoor explosion-proof lighting applications where corrosion is less of a concern.

Lens Material

In addition to the enclosure, the lens material plays a critical role in explosion-proof lights. Lenses made from tempered glass or polycarbonate are highly resistant to impact and high temperatures, ensuring they don&#;t shatter or become damaged in the case of an explosion.

Tempered glass offers superior clarity, while polycarbonate lenses provide enhanced impact resistance, making them ideal for environments with high mechanical stress.

Environmental Considerations

Material selection directly impacts the lighting's performance in extreme environments. Offshore oil rigs, for example, expose lighting systems to corrosive saltwater and constant humidity, which makes stainless steel a more suitable option due to its higher resistance to corrosion. In chemical plants, where exposure to corrosive substances and high temperatures is common, explosion-proof lights made from materials like stainless steel or coated aluminium are crucial to prevent rapid degradation. The ability of these materials to withstand such conditions ensures that the lights remain operational and safe, reducing the need for frequent replacements and maintenance.

&#;&#; Performance Standards for Industrial Lighting

Proper lighting in industrial settings is crucial for ensuring worker safety, productivity, and operational efficiency. Measured in lux (lumens per square metre), illumination levels vary based on the specific tasks performed and the age of the workers. As eyesight diminishes with age, older workers require higher lux levels to maintain performance. The following chart outlines the recommended lux levels for various applications, addressing the differing needs of employees aged 25-60 and those aged 60 and above.

Recommended Lux Levels for Various Applications

&#;&#; Case Study: Enhancing Safety and Efficiency in a Chemical Processing Plant

The Problem: In a large chemical processing plant, inadequate lighting in hazardous areas led to safety risks and frequent near-misses during night-time operations. Workers struggled to perform tasks safely, particularly during quality inspections, resulting in increased downtime and reduced productivity.

The Solution: To address these challenges, the plant upgraded to SharpEagle's explosion-proof LED lighting. This lighting solution provided higher lux levels and improved light distribution, ensuring compliance with safety standards. The new system was installed in critical areas, such as processing lines and inspection stations, significantly enhancing visibility.

Results: After implementing SharpEagle's explosion-proof lighting, the plant experienced a remarkable transformation:

The incidence of workplace accidents decreased by 61%, significantly enhancing worker safety.
Operational efficiency improved by 33%, as workers could perform tasks more effectively under better lighting conditions.
The facility achieved a 48% reduction in energy costs due to the energy-efficient design of the LED lights, contributing to lower operational expenses.

Overall, the switch to SharpEagle's explosion-proof lighting not only created a safer working environment but also led to substantial improvements in productivity and cost savings.

&#;&#; Comparative Analysis: Explosion-Proof LED Lights vs. Traditional Lighting

When comparing explosion-proof LED lights with traditional incandescent or fluorescent options, several benefits emerge in favour of ex-proof lights, owing to its diverse applicability in high-risk zones.

Energy Efficiency

Ex-proof LEDs offer up to 90% energy savings compared to traditional lighting solutions. For industries with extensive lighting requirements, these savings can translate into substantial cost reductions over time.

Lifespan and Maintenance

Explosion-proof LED lights have a much longer lifespan, of up to 100,000 hours, compared to traditional lights, which typically last between 10,000 to 25,000 hours. The reduced need for replacements and maintenance makes LEDs the more cost-effective option in the long run.

Safety Features

LEDs also feature advanced resistance to extreme weather conditions, reducing the risk of damage as well as ignition with any surrounding gases or vapours. This makes explosion-proof LED lights inherently safer than traditional incandescent or fluorescent bulbs. Additionally, LED technology provides superior light quality, which enhances visibility in hazardous areas, further boosting safety for workers.

Sustainability

Another critical advantage is that LEDs are more environmentally friendly. The reduced energy consumption lowers the overall carbon footprint, and since LEDs last longer, fewer lights need to be replaced, minimising waste.

&#;&#; The Future of Explosion-Proof Lighting

With growing demand for improved safety standards and energy efficiency, the explosion-proof lighting market is set to expand significantly. The future of this market lies in the adoption of LED technologies, advanced materials, and smarter systems that can integrate with industrial IoT (Internet of Things) platforms.

The shift towards explosion-proof lighting from stainless steel is another notable trend. Stainless steel is more resistant to corrosion, which makes it ideal for harsh environments like offshore oil rigs, marine settings, or chemical processing plants. The durability and low maintenance needs of such materials make them increasingly popular for businesses looking to reduce long-term costs.

&#;&#; Conclusion

The Explosion-proof lighting market is experiencing significant growth, with a projected CAGR of approximately 6.5% from to . This expansion is driven by increasing demand in sectors such as oil and gas, petrochemicals, and pharmaceuticals where hazardous atmospheres are common. As industries prioritise workplace safety, the shift towards durable materials, especially explosion-proof lighting made from stainless steel, has become essential due to its superior resistance to corrosion and wear. Additionally, the demand is rapidly rising as companies seek more energy-efficient and sustainable solutions. Whether it's the use of explosion-proof LED lights or explosion-proof area lighting, selecting the correct solution for your environment can make all the difference.

At the same time, due to the market clutter, it is often challenging for new buyers to find their right ex-proof investment and partner with reliable safety solution providers. Irrespective of the industry, explosion-proof lighting needs to be energy-efficient with LEDs, built from durable materials like stainless steel, and adhering to global standards like ATEX and IECEx. From oil and gas refineries to chemical plants, investing in the right lighting technology will not only enhance safety but also provide long-term economic benefits.

If you&#;re looking to upgrade your lighting solutions or need guidance on selecting the right explosion-proof lighting in the GCC and UK, explore our range of products at SharpEagle. We are your end-to-end safety consultants, specialising in advanced lighting solutions tailored to hazardous environments, ensuring both compliance and safety for your industrial operations.

Intrinsically Safe vs Explosion Proof Lights